Reinforced water-resistant board with traffic coat

ABSTRACT

A reinforced water-resistant board includes a cover board with a reinforced water-resistant membrane applied to a surface of the cover board. The reinforced water-resistant membrane includes a primer layer, a reinforced membrane, a traffic coat, and a sealing layer. The primer layer is applied over the surface of the cover board. The reinforced membrane includes fleece soaked in a liquid resin and is applied over the primer layer. The traffic coat is boned to the reinforced member. The sealing layer is applied over the traffic coat.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 14/074,909, filed on Nov. 8, 2013, now U.S. Pat. No. 9,267,285,the entire contents of which is hereby incorporated by reference.

BACKGROUND

1. Technical Field

The present disclosure relates to construction materials and, morespecifically, to a construction board with a pre-applied water-resistantcoating.

2. Background

Water-resistant describes objects relatively unaffected by water orresisting the ingress of water under specified conditions. “Waterresistant” often refers to penetration of liquid water. In construction,a building or structure is made water-resistant with the use ofmembranes and coatings to protect contents underneath or within as wellas protecting structural integrity. Water-resistance is not limited toroofing. Moreover, roofing does not necessarily mean that it iswater-resistant.

In commercial, residential, and industrial constructions and buildings,the conventional system of water-resistance involves “membranes.” Thisrelies on the application of one or more layers of membrane (availablein various materials: e.g., bitumen, silicate, polyvinyl chloride (PVC),ethylene propylene diene monomer (EPDM), etc.) that act as a barrierbetween the water and the applicable spaces, preventing the passage ofwater. However, the membrane system relies on exacting application,presenting many difficulties such as problems with application andadherence to the substrate can lead to leakage.

In general, one or more layers of membrane systems are separatelymanufactured and separately and successively applied to thesubstrate/surface and applicable penetrations. This requires applicationas per manufacturer's instructions and specifications,qualified/experienced applicators, and most important for exterior workor roofs, good weather conditions. Once completed, installation ofoverboard (such as wood decks, pavers, titles, etc.) is required toprotect membrane from punctures and allow foot traffic.

SUMMARY

In an aspect of the present disclosure, a reinforced water-resistantboard includes a substrate, a primer layer, a reinforced membrane, atraffic coat, and a sealing layer. The primer layer is applied over asurface of the substrate. The reinforced membrane is applied over theprimer layer and includes a liquid resin absorbed in fleece. The trafficcoat is applied over and bonded to the reinforced membrane. The sealinglayer is applied over the traffic coat. In embodiments, the substrateincludes a key protruding from a first edge and defines a keyway in asecond edge.

In aspects of the present disclosure, a method of manufacturing areinforced water-resistant board includes forming a reinforced membraneincluding soaking fleece in a liquid resin, applying the reinforcedmembrane over the surface of a substrate, and spreading a traffic coatover the reinforced membrane before the liquid resin cures. The methodmay include applying a primer layer to a surface of a substrate andcuring the primer layer. The reinforced membrane may be applied over thecured primer layer. The method may include applying a sealing layer overthe traffic coat. In embodiments, the method includes permitting thereinforced membrane to cure before applying a sealing layer over thetraffic coat.

In aspects of the present disclosure, applying the reinforced membraneincludes spreading the liquid resin over the primer layer and laying thefleece over the liquid resin spread over the primer layer. Applying thereinforced membrane may include rolling the fleece to remove air bubblesfrom the reinforced membrane. Forming the reinforced membrane mayinclude spreading additional liquid resin over the reinforced membraneover the fleece laid over the liquid resin.

In aspects of the present disclosure, a water-resistant system includesa plurality of reinforced water-resistant boards and a joint sealingsystem. Each of the plurality of reinforced water-resistant boards maybe any of the reinforced water-resistant boards described herein. Thejoint sealing system is applied over the joints between each of theplurality of reinforced water-resistant boards. The joint sealing systemincludes a sealing compound placed in each of the joints and a sealingstrip laid over each of the joints.

By prefabricating the reinforced water-resistant boards, the applicationof the water-resistant systems may be simplified. For example, theprefabricated boards may be used without the need for using torches orkettles to heat a water-resistant membrane or material in the field.Moreover, by prefabricating the reinforced water-resistant boards, in afactory within a controlled environment the adhesion of thewater-resistant membrane to the substrate may be more consistent andless prone to defects than a water-resistant membrane applied in thefield. The prefabricated reinforced water-resistant board may have alonger life cycle and may be universally used in a variety ofapplications including but not limited to flat roofs, sloped roofs,balconies, patios, basements, exterior walls, interior walls, floors,etc. In addition, the use of prefabricated reinforced water-resistantboards may reduce the amount of time and activities are required toinstall the boards decreasing the likelihood of accidents and defectsduring the installation of the water-resistant systems. Further, usingprefabricated reinforced water-resistant boards may decrease the delaysin installing a water-resistant system due to weather or environmentalconditions, e.g., curing times, humidity, sun exposure, etc. Theprefabricated reinforced water-resistant boards may also reduce the needfor temporary water-resistant system to be installed before the finalwater-resistant system is available, e.g., temporary roof.

By not requiring the use of an over-material, e.g., shingles, tiles,decking, the water-resistant boards may provide a lighter weightwater-resistant solution, which may reduce the needed structural supportand/or reduce the risk of structural collapses.

Reducing the amount of time required to install a water-resistant systemby using prefabricated reinforced water-resistant boards the labor costof the installation may be reduced. Moreover, the installation ofprefabricated reinforced water-resistant boards may reduce the need forskilled water-proofers and roofers permitting lower skilled laborers toinstall the water-resistant system.

Certain embodiments of the present disclosure may include some, all, ornone of the above advantages. One or more other technical advantages maybe readily apparent to those skilled in the art for the figures,descriptions, and claims included herein. Moreover, while specificadvantages have been enumerated above, various embodiments may includeall, some, or none of the enumerated advantages.

Further, to the extent consistent, any of the aspects described hereinmay be used in conjunction with any or all of the other aspectsdescribed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present disclosure are described hereinbelow withreference to the drawings, wherein:

FIG. 1 is an exploded perspective view showing the layers of anexemplary embodiment of a reinforced water-resistant board in accordancewith the present disclosure;

FIG. 2 is a perspective view of an embodiment of a water-resistantsystem in accordance with the present disclosure including a tworeinforced water-resistant boards attached to structural members;

FIG. 3 is a front cross-sectional view of the water-resistant system ofFIG. 2 taken along the center line of one of the structural members; and

FIG. 4 is a top view of another embodiment of a water-resistant systemincluding a plurality of reinforced water-resistant boards.

DETAILED DESCRIPTION

Embodiments of the present disclosure are now described in detail withreference to the drawings in which like reference numerals designateidentical or corresponding elements in each of the several views.

Referring now to FIG. 1, a reinforced water-resistant board 10 isprovided in accordance with the present disclosure including a substrateor cover board 20 and a reinforced water-resistant membrane 30. Thereinforced water-resistant membrane 30 includes a primer layer 32, areinforced membrane 34, a traffic coat 38, and a sealing layer 39.

The reinforced water-resistant board 10 is manufactured by applying theprimer layer 32 to a surface 21, 22 of the cover board 20, applying thereinforced membrane 34 over the primer layer 32, applying the trafficcoat 38 over the reinforced membrane 34, and applying the sealing layer39 over the traffic coat 38. As detailed below, the reinforcedwater-resistant membrane 30 is applied to surface 21 of the cover board20; however, it is contemplated that the reinforced water-resistantmembrane 30 may be applied to both the surface 21 and the surface 22 ofthe cover board 20. In embodiments, the reinforced water-resistantmembrane 30 is applied to surfaces 21 and 22 of the cover board 20simultaneously. In some embodiments, the reinforced water-resistantmembrane 30 is applied to one of the surfaces 21, 22 of the cover board20 and then to the other one of the surfaces 21, 22 of the cover board20. Applying the reinforced water-resistant membrane to both of thesurfaces 21 and 22 may protect the cover board 20 from moisturepenetrating the cover board 20 through either of the surfaces 21, 22.

The cover board 20 may be constructed of any suitable constructionmaterial, e.g., a plywood board, a cement board, a blue board, etc. Thecover board 20 may be provided in standard construction lengths andwidths, e.g., 8′×4′, 8′×6′, 5′×3′, 4′×4′, 12′×2′, 12′×26″, 8′×26″, or incustomer sizes. The cover board 20 may be provided in varying thicknessin a range of about ⅛″ to about 2″, e.g., ¼″, 3/16″, ⅜″, ½″, 5/16″, ⅝″,¾″, 1″. Two edges of the cover board 20, e.g., an edge 24, may include akeyway 26 and two edges 27, 28 of the cover board 20 may include a key29. The keyway 26 of one cover board 20 is configured to receive the key29 of another cover board 20 to interlock adjacent cover boards. The key29 may extend in a range of about ⅛″ to about ½″ from the edge 27, 28 ofthe cover board 20. The key 29 may be substantially centered along anedge 27, 28 of the cover board 20 as shown in FIG. 1. In embodiments,the key 29 is positioned adjacent a surface 21, 22 along an edge 27, 28of the cover board 20.

The primer layer 32 is applied to surface 21 of the cover board 20. Theprimer layer 32 is permitted to cure after being applied to the surface21. The primer layer 32 may cure in a range of about 1 hour to about 8hours, e.g., 1, 1.5, 2, 2.5, 3, 3.5, 4, 5, 6, 7, 8 hours, etc.

The reinforced membrane 34 includes fleece 35 that absorbs a liquidresin 36. The reinforced membrane 34 may be applied by applying theliquid resin 36 over the cured primer layer 32, spreading the fleece 35over the liquid resin 36, and applying additional liquid resin 36 overthe fleece 35. A roller (not shown) may be rolled over the fleece 35 andthe liquid resin 36 to remove air bubbles from within the reinforcedmembrane 34. In embodiments, the reinforced membrane 34 may be appliedby soaking the fleece 35 in a liquid resin 36 until the fleece 35absorbs the liquid resin 36. The soaked fleece 35 is laid over the curedprimer layer 32. In some embodiments, the reinforced membrane 34 isapplied over the cured primer layer 32 by laying the fleece 35 over thecured primer layer 32 and spreading the liquid resin 36 over the fleece35 until the fleece 35 absorbs the liquid resin 36. When the soakedfleece 35 cures, the soaked fleece 35 forms the reinforced membrane 34.The soaked fleece 35 may cure in the range of about 1 hour to about 8hours, e.g., 1, 1.5, 2, 2.5, 3, 3.5, 4, 5, 6, 7, 8 hours, etc.

The traffic coat 38 is spread over the reinforced membrane 34 before thesoaked fleece 35 cures. The traffic coat 38 may be dry silica sand orquartz sand spread over the soaked fleece 35. In embodiments, thetraffic coat 38 covers the entire surface of the reinforced membrane 34such that no wet spots of the reinforced membrane 34 are visible. Thewet surface of the soaked fleece 35 bonds with the traffic coat 38 asthe soaked fleece 35 cures. The traffic coat 38 protects the reinforcedmembrane 34 from damage. The traffic coat 38 may protect the reinforcedmembrane 34 from punctures. The traffic coat 38 may allow foot trafficon top of the reinforced member 34 eliminating the need for an overlayer such as wood decking, pavers, tiles, shingles, etc.

The sealing layer 39 is applied over the traffic coat 38 after thereinforced membrane 34 cures and bonds with the traffic coat 38. Thesealing layer 39 is spread over the traffic coat 38 to prevent liquidpenetration into the reinforced membrane 34. The sealing layer 39 ispermitted to cure. The sealing layer 39 may cure in the range of about 1hour to about 4 hours, e.g., 1, 1.5, 2, 2.5, 3, 3.5, 4 hours, etc.

The cover board 20 may include one or more of cement board, plywood,fiberboard, blue board, or composite board. “Cement board” should beunderstood to include a variety of products including but not limited toone or multi component cement aggregates and reinforcements. “Plywood”should be understood to include a variety of products including but notlimited to 1 ply, 3 ply, sanded, unsanded, sheathing, nonsheathing,finished, unfinished, pine, birch, maple, cedar, etc. The followingcommercially available substrates or cover boards may be used as thecover board 20: WonderBoard® backerboard, Durock® cement board, ProjectPanels, Hunter panels, Plytanium®, Sopraboard, etc.

The primer layer 32 may include one, two, or multi component epoxy,waterborne epoxy, water-based epoxy, liquid epoxy resins, acrylic,liquid polyurethane resins, liquid methyl methacrylate resin, polymethylmethacrylate (PMMA) primers, thixotropic PMMA resins, catalyzed PMMAprimers or coatings, etc. The primer layer 32 may be provided as aliquid. The primer layer 32 may be a cold-applied liquid primer.Suitable primers that may be used to form the primer layer 32 arecommercially available from Kemper System, Soprema®, Sika, Behr,Siplast®, SEAL-KRETE®, etc. Exemplary materials may be but are notlimited to Sikafloor® FTP, Kempertec® Primer, Kempertec® EP Primer,Kempertec® AC Primer, Kempertec® BSF-R Primer/Sealer, Alsan® RS 222Primer, Alsan® RS 276 Primer, Siplast® Pro Primer R Resin, Siplast® ProPrimer W Resin, BEHR PREMIUM® Concrete & Masonry Bonding Primer, etc.

The fleece 35 of the reinforced membrane 34 may include one or morepolyester layers, cotton layers, fiberglass fabric layers, reinforced ornon-reinforced, coated or non-coated, saturated or non-saturated,non-woven, needle-punched, stitch-bonded, heat-set, or cold processspun. Suitable materials that may be used as the fleece 35 arecommercially available from Kemper Systems, Soprema®, Siplast®, Sika,etc. Exemplary materials may be but are not limited to Alsan® RS Fleece,Kemperol® Fleece 200, Kemperol® Fleece 165, Kemperol® Fleece AP 120,Siplast® Pro Fleece, Sikalastic® Fleece-120, etc.

The liquid resin 36 of the reinforced membrane 34 may include one ormore of polyurethane, catalyzed PMMA, PMMA acrylic resin, aliphaticpolyurethane, electrometric polyurethane, siliconized elastomericacrylic, elastomeric acrylic, ceramic elastomeric, acrylic, acryliclatex, methyl methacrylate, polyester, waterborne resins or coatings,etc. any of which may be one, two, or multi-component, fast or slowcuring, aromatic or odorless. The liquid resin 36 may be a cold-appliedliquid resin. Suitable liquid resins that may be used as the liquidresin 36 are commercially available from Kemper System, Soprema®, Sika,Behr, Henry, Siplast®, Gardner-Gibson, SEAL-KRETE®, etc. Exemplarymaterials may be but are not limited to Alsan® RS 230 Field, Kemperol®2K-PUR, Kemprol® AC, Kemperol® BR, Kemperor® BRM, Kemprol® V210,Kemperol® V210M, Siplast® Parapro Flashing Resin, Siplast® Parapro RoofMembrane Resin, Sikalastic®-560, Sikalastic®-710 Base, Sikalastic®-720Base, Sikalastic®-745AL, Sikalastic®-715 Top, Black Jack® 5530-1-30(Ultra-Roof 1000), Black Jack® 5227-1-20 (Roof Patch), Black Jack®5527-1-30 (Roof-Gard 700), Black Jack® 532-1-30 (Maxx-Cool), Black Jack®6030-7-20 (Foundation Waterproof Coating), etc.

The traffic coat 38 may be a combination of one or more of resin,fleece, silica sand, and sealer. Suitable sizes for sand used as thetraffic coat may be in a range of about −1 to about 4 on the KrumbeinPhi Scale. Suitable traffic coats that may be used as the traffic coat38 are commercially available from Kemper System, Soprema®, Sika, Behr,Henry, Gardner-Gibson, SEAL-KRETE®, Siplast®, etc. Exemplary materialsmay be but are not limited to Surfacing Sand #0 from Kemper Systems, 3MColorquart®, etc.

The sealing layer 39 may include one or more of concrete, brick, orroofing sealers including but not limited to polyurethane, aliphaticpolyurethane, water-based acrylic, acrylic resin, epoxy, epoxy acrylic,water-based, waterborne, waterborne epoxy, siliconized elastomericacrylic, elastomeric acrylic, ceramic elastomeric, acrylic latex, methylmethacrylate, silicate, silane siloxane, and polyester sealers orcoatings, etc. which may be one, two, or multi component, fast or slowcuring, aromatic or odorless, and from glossy to flat finish. Thesealing layer 39 may be provided in liquid form. In embodiments, thesealing layer 39 is a cold-applied liquid sealer. Suitable sealers thatmay be used as the sealing layer 39 are commercially available fromJohns Manville, Kemper System, Sika, Behr, Henry, Gardner-Gibson,SEAL-KRETE®, Siplast®, etc. Exemplary materials may be but are notlimited to Kemperdur® Eco Finish, Kemperdur® Finish, Kemperdur® DekoTransparent, Kemperdur® FC Floor Coating, Keperdur® EP-FR Finish,Kemperdur® Deko Finish, Kemperdur® BSF-R Finish, Kemperdur® Deko 2KS-FRFinish, Kemperdur® AC Finish, Sikalastic®-745AL, Sikalastic®-715 Top,BEHR PREMIUM® 1 Part Epoxy Concrete Floor Paint, SEAL-KRETE® OriginalWaterproofing Sealer, SEAL-KRETE® Epoxy Seal Slate Concrete and GarageFloor Paint, Black Jack® 5530-1-30 (Ultra-Roof 1000), Black Jack®5227-1-20 (Roof Patch), Black Jack® 5527-1-30 (Roof-Gard 700), BlackJack® 5532-1-30 (Maxx-Cool), Black Jack® 6030-7-20 (FoundationWaterproof Coating), etc.

It is contemplated that reinforced membrane 34, the traffic coat 38,and/or the sealing layer 39 may be provided in a variety of colorsincluding but not limited to black, gray, white, brown, silver, etc.

With reference to FIGS. 2-4, a water-resistant system 100 in accordancewith the present disclosure includes a plurality of reinforcedwater-resistant boards 10 and a joint sealing system 150. Thewater-resistant system 100 may be used in a variety of applicationsincluding but not limited to new roofs (flat and sloping), roof repair,roof recovery, balconies, terraces, patios, decks, basement finishing,exterior walls, interior walls (e.g., bathrooms, kitchens, laundryrooms, utility rooms, etc.), interior floors, etc.

A first board 10 a is attached to one or more structural member(s) 80,e.g., rafters, floor boards, joists, framing, etc, of a structure to bemade water-resistant, e.g., a floor, a roof, etc. Each board 10 may beattached to the structural member(s) 80 by one or more fastener(s),e.g., nails 102, screws 104, and/or adhesives 106. As shown in FIG. 3,board 10 a is attached to the structural member 80 by a nails 102 andadhesive 106 and board 10 b is attached to the structural member 80 byscrews 104. The fastener(s) may be driven through the board 10 a, 10 band into the structural member 80. A first row of boards 120 is formedby placing a second board 10 b adjacent to the first board 10 a. Twoadjacent boards may be interlocked by inserting a key 29 of the firstboard 10 a into a keyway 25 of the second board 10 b. In embodiments,the boards 10 are interlocked by being placed adjacent to one anotherwith a minimum gap between the boards 10 a, 10 b. The interlocked secondboard 10 b is attached to the structural member(s) 80 in a mannersimilar to the first board 10 a. This process of placing and/orinterlocking and attaching boards 10 is continued until the first row ofboards 120 is complete. A second row of boards 130 is formed in asimilar manner to the first row of boards 120 with the addition ofplacing and/or interlocking an edge of each board 10 in the second rowof boards 130 with an edge of the first row of boards 120. It is alsocontemplated, that the joints between boards in the second row of boards130 are offset from the joints between boards in the first row of boards120 as shown in FIG. 4. Successive rows of boards are added to thewater-resistant system 100 until the entire structure is covered by thewater-resistant system 100. It is contemplated that portions of boards10 of the water-resistant system 100 may extend beyond the structuralmember(s) 80 that the water-resistant is attached. This extension mayform an overhang or eave.

The joints between the boards 10 are sealed with the joint sealingsystem 150. The joint sealing system 150 may include a sealing compound152 and/or a sealing strip 154. The sealing compound 152 is applied tothe joint between the edges of adjacent boards 10 a, 10 b as shown inFIG. 2. The sealing compound 152 may be a caulking material such aspolyurethane caulking, e.g., MP1, Sica, etc. The sealing strip 154 isapplied over the joint between two adjacent boards 10 a, 10 b. Thesealing strip 154 may have a width such that the sealing strip 154covers the top of fasteners, e.g., nails 102, screws 104, driven throughadjacent boards 10 a, 10 b to secure the boards 10 a, 10 b to thestructural member(s) 80. The joint sealing system 150 seals any gapsbetween adjacent boards 10 a, 10 b to provide a continuouswater-resistant seal across water-resistant system 100. It iscontemplated that the sealing strip 34 may be made similar to thereinforced membrane 30 including fleece and liquid resin, e.g., thefleece 35 and the liquid resin 36. In embodiments, the sealing strip 34is about 4 inches wide; however, the sealing strip 34 maybe thinner orwider than 4 inches. It is understood that the sealing strip 34 is wideenough to cover the joints between adjacent boards and to cover the topsof the fasteners driven through adjacent boards. It is contemplated thatsealing strips 34 may cover the entire surface or surfaces of thewater-resistant system 100. It is contemplated that the prefabricatedreinforced water-resistant boards may be incorporated into existingwater-resistant systems already available on the market such as theKemper System, the Black Jack® System, the Soprema® System, the Siplast®System, etc.

It will be appreciated that the boards 10 of water-resistant system 100are adjacent and not overlapping that the boards 10 may be laid in anyorder. For example, a water-resistant system 100 forming a sloped roofmay be started by first attaching the boards adjacent to the bottom ofthe roof, may be started by first attaching the boards forming the peakof the roof, or may be started at any place in the middle of the roof.This allows for flexibility for the construction, which allows areas ofthe roof to be completed before other portions permitting access to someareas while water-resistant other portions of the structure.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Any combination ofthe above embodiments is also envisioned and is within the scope of theappended claims. Therefore, the above description should not beconstrued as limiting, but merely as exemplifications of particularembodiments. Those skilled in the art will envision other modificationswithin the scope and spirit of the claims appended hereto.

What is claimed:
 1. A method of manufacturing a reinforcedwater-resistant board comprising: forming a reinforced membraneincluding soaking fleece in a first liquid resin; applying thereinforced membrane over a surface of a substrate; and spreading sanddirectly over the reinforced membrane after applying the reinforcedmembrane over the surface of the substrate before the first liquid resincures.
 2. The method according to claim 1, further comprising applying aprimer layer to a surface of a substrate and curing the primer layer,wherein the reinforced membrane is applied over the cured primer layer.3. The method according to claim 2, wherein applying the reinforcedmembrane includes spreading the first liquid resin over the primer layerand laying the fleece over the first liquid resin spread over the primerlayer.
 4. The method according to claim 3, wherein applying thereinforced membrane further includes rolling the fleece to remove airbubbles from the reinforced membrane.
 5. The method according to claim3, wherein forming the reinforced membrane includes spreading a secondliquid resin over the fleece laid over the first liquid resin.
 6. Themethod according to claim 1, further comprising applying a sealing layerover the sand.
 7. The method according to claim 6, further comprisingpermitting the reinforced membrane to cure before applying the sealinglayer over the sand.
 8. The method according to claim 1, wherein atleast one of forming the reinforced membrane, applying the reinforcedmembrane, and spreading the sand is applied by hand.
 9. The methodaccording to claim 1, wherein at least one of forming the reinforcedmembrane, applying the reinforced membrane, and spreading the sand isapplied mechanically.
 10. A method of manufacturing a water-resistantboard comprising: applying a primer layer to an outer face of asubstrate, the outer face configured to be exposed after installation ofthe water-resistant board; forming a reinforced membrane over the primerlayer after the primer layer is applied to the outer face of thesubstrate; and applying sand directly over the reinforced membrane afterforming the reinforced membrane.
 11. The method according to claim 10,further comprising allowing the primer layer to cure before forming thereinforced membrane over the primer layer.
 12. The method according toclaim 10, wherein forming the reinforced membrane includes: spreading afirst liquid resin over the primer layer; and laying a fleece in thefirst liquid resin.
 13. The method according to claim 12, whereinforming the reinforced membrane further includes: spreading a secondliquid resin over the fleece laid in the first liquid resin.
 14. Themethod according to claim 13, wherein spreading the second liquid resinover the fleece laid in the first liquid resin occurs after the firstliquid resin with the fleece has cured.
 15. The method according toclaim 12, wherein spreading the first liquid resin over the primer layeroccurs before the primer layer cures.
 16. The method according to claim10, wherein forming the reinforced membrane includes: soaking a fleecein a first liquid resin such that the fleece absorbs the first liquidresin; and laying a fleece in the primer layer.
 17. The method accordingto claim 10, further comprising applying a sealing layer over the sand.18. The method according to claim 10, further comprising allowing thereinforced membrane to cure before applying the sand over the reinforcedmembrane.
 19. The method according to claim 10, further comprising:applying an inner primer layer to an inner face of a substrate, theinner face opposite the outer face; forming an inner reinforced membraneover the inner primer layer.
 20. A method of manufacturing awater-resistant board comprising: soaking a fleece in a first liquidresin such that the fleece absorbs the first liquid resin; applying thesoaked fleece to an outer face of a substrate, the outer face configuredto be exposed after installation of the water-resistant board; andapplying a traffic coat over the soaked fleece after the soaked fleeceis applied to the outer face of the substrate.